Chamber cluster for a co-axial damper unit in a suspension module

ABSTRACT

A chamber cluster ( 1 ) for a co-axial damper unit, used in a suspension module, that is driven by the motion of a torsion bar ( 2 ), that transmits the rotational motion through gears ( 3 ), ( 4 ), ( 5 ) to a wing ( 6 ), enclosed within. The rotary motion of the wing ( 6 ), in a viscous medium in a volumous space ( 19 ), sealed by seals ( 10 ), ( 11 ), achieves damping by enclosing the wing ( 6 ), inside a W-shaped flexible component ( 7 ), and by the use of a two-phase viscous fluid, that is subject to a viscosity variation, by means of electromagnetic control through a device ( 15 ). Several chamber cluster ( 1 ) units connected via a bulkhead ( 20 ), create an assembly forming the co-axial damper unit, for use in a suspension module.

The present invention relates to a chamber cluster for a co-axial damper unit, driven by a torsion bar, in a suspension module of a car. The existing damping arrays, in automotive applications, range from anti-roll bar uses, as in Pask (1999), to an entire suspension module arrangement, in Hatzikakidis (2011).

These prior art cases include: The rotary actuator for active roll control by M. Pask (1999), the rotary damper by M. Oliver (2002), the stabilizer bar with variable torsional stiffness by M. Gradu (2004), the suspension arrangement by S. Zetterstrom (2008), and the rotary damper arrangement for torsion bars for vehicles, by D. Hatzikakidis (2011).

The object of the present invention is the integration of a chamber cluster into an assembly that makes up a co-axial damper unit, and then, in turn, integrated into a suspension module of a vehicle.

The resulting suspension module is made up of many independent chambers, utilizing the primary motion of the torsion bar, (which acts as the “spring” of the suspension module). The assembly of the co-axial damper unit, comprises several sets of gear drives, incorporating several idle gears to drive the corresponding damping wing surfaces. Furthermore, each chamber cluster houses a W-shaped flexible component, enclosing each damping wing. The resulting co-axial damper unit, made up of an assembly of several chamber clusters, can provide variable damping characteristics, by varying the pressure of the fluid and by varying the viscous characteristics of the fluid, inside the chambers, by electromagnetic and magnetic means.

A “single chamber cluster” notion, that “builds” the required “damper unit”, offers advantages in design and production terms.

According to the invention, the objective is achieved by the use of separate multiple chamber cluster units joined together, so that the resulting co-axial damper can achieve optimal damping and cooling, and offer variable damping characteristics, as defined in independent claim 1. The dependent claims define preferred embodiments of the invention.

In the following, a preferred embodiment of the invention will be discussed in more detail, with reference to the accompanying drawings.

The invention will be made conceivable with reference to the designs that accompany the present description, in which certain proposed industrial applications of the invention are shown.

FIG. 1 shows a view of one chamber cluster, its constituent parts, and how it is attached to (the driving) torsion bar, of the suspension module.

FIG. 2 depicts the constituent parts of the chamber cluster, in section.

FIG. 3 shows a detailed view of the gear drive, the wing and the W-shaped flexible component, inside the chamber.

FIG. 4 depicts the resulting assembly of several chamber clusters, making up the co-axial damper unit of a suspension module.

FIG. 1-FIG. 4 show a preferred embodiment of the invention. While this particular embodiment will be described in detail below, several modifications will be appreciated by a person skilled in the art, so that the invention shall not be interpreted in a limited manner, referring to the description and the drawings. Rather the invention is defined by the appended claims.

Referring to a selected indicative example of industrial application of the invention, a number of the main sections and components of the device are listed below. More specifically, the basic parts of the invention are the following:

-   1. Chamber cluster, that encloses one damper wing. -   2. Torsion bar (suspension spring). -   3. Drive gear (fitted onto the torsion bar). -   4. Idle gear, (transfering the motion of the drive gear, to the wing     gear). -   5. Wing gear. -   6. Wing. -   7. Flexible component (W-shaped wing-enclosure). -   8. Assembly cover. -   9. Outer gear locator bracket, (holding/controlling parts 4,5,16,17) -   10. Outer seals. -   11. Inner seals. -   12. Inner gear locator bracket, (holding/controlling parts     4,5,16,17) -   13. Pressure control valve. -   14. Flexible part of the wing. -   15. Electromagnetic device that affects the viscosity of the damper     fluid. -   16. Axis of rotation of the idle gear. -   17. Axis of rotation of the wing gear. -   18. Axis of rotation of the torsion bar. -   19. Viscous fluid volume space. -   20. Assembly bulkhead.

In FIGS. 1-4, reference numeral 1 designated the chamber cluster. The chamber cluster (1), shown in FIGS. 1 and 2, encloses the constituent parts (4), (5), (6), (7) that are connected to the torsion bar (2), via the assembly bulkhead (20).

The rotary motion of the torsion bar (2), (due to the suspension travel), is transmitted via the drive gear (3), to the damping wing (6), via gears (4) and (5). Gears (4), (5) rotate about axes (16), (17) respectively. Gear (3), rigidly attached to the torsion bar (2), rotates about an axis (18).

According to the preferrred embodiment shown, the chamber cluster (1), shown in FIG. 1, encloses a damping wing (6) that is enclosed in a W-shaped flexible component (7). (FIG. 3)

The rotational motion (FIG. 3), of the damping wing (6), takes place inside the volume space (19). This volume is filled with a viscous fluid, and is formed by the assembly of several chamber clusters around the torsion bar (2), about an axis (18). (FIG. 4, FIG. 1). This assembly is formed using the bulkhead (20).

In FIG. 3, the shape of the W-shaped component (7), is shown in section. This flexible component is closed at the top and open at the lower end, allowing the positioning of the wing (6), inside part (7), occupying the viscous fluid volume (19), within the chamber cluster (1). The rotation of wing (6) creates damping.

The pressure of the fluid in volume (19) is regulated via the valve (13). The viscosity of the fluid can be varied through the electromagnetic device (15), that encloses the chamber cluster (1). FIG. 2. In this case, the viscous fluid becomes a two phase fluid.

Within the chamber cluster (1), the outer gear locator bracket (9) and the inner gear locator bracket (12), position the axes of rotation (16),(17) of gears (4),(5) respectively. The volume (19) is sealed via outer seals (10) and inner seals (11), in sliding contact with the torsion bar (2), which is sealed with the assembly cover (8), and connected to the assembly bulkhead (20). FIG. 2.

The use of the flexible part of the wing (14), attached to wing (6), is associated with the flexible component (7), and the use of a two-phase fluid in volume (19), subject to an electromagnetic device (15), that alters the viscosity of the fluid, offering variable damping characteristics to the damper unit and the suspension module.

The resulting assembly (FIG. 4), is formed by the succesive positioning of several chamber cluster (1) units, about the axis (18), and the suspension module torsion bar (2), connected via the bulkhead (20), and the assembly cover (8).

In FIG. 4 a five-chamber-cluster (1) assembly is, indicatively, shown. 

1. A chamber cluster for a co-axial damper unit of a suspension module, comprising a damping wing, enclosed in a flexible component, in contact with the inner surface of the chamber, that allows the rotation of the wing, in a volume space, filled with a viscous medium, whose pressure is controlled by a pressure control valve, that is driven by the motion of the torsion bar of the suspension module, that rotates about an axis, that is rigidly attached to a first drive gear, via the coupling of an idle gear, and a second drive gear, connected to the wing, that moves within the volume, that is sealed by outer seals, and inner seals, sealing the torsion bar, the chamber cluster, a bulkhead and an assembly cover, that positions the outer gear locator bracket, and the inner gear locator bracket, orienting the axes of rotation, of the idle gear and the drive gear, that performs variable damping on to the torsion bar, due to the motion of wing in volume, producing variable viscosity characteristics, inducing a two-phase viscous fluid condition, by electromagnetic means via device, attached to the chamber cluster, and/or being in electromagnetic interference with the fluid, therein, that features the flexible component, that has a W-shaped cross-section, with a closed top section, in contact with the inner chamber cluster, and an open lower section, that allows the enclosure of the wing into the flexible component part, and allows the partial sealing of the volume space, during the rotation of wing, thus achieving damping, featuring the total volume that is the sum of the internal volumes of the constituent chamber cluster units, and by using the bulkhead, forms the assembly of the co-axial damper, that, in turn, creates the assembly of a co-axial damper unit, that, in turn, creates a suspension module.
 2. The chamber cluster for a co-axial damper unit of a suspension module, according to claim 1, comprising the volume space, such that gear is sealed away from the viscous medium of the chamber cluster, so that the coupling of the first drive gear, idle gear and second drive gear, is performed externally (without being in contact with the viscous medium). The shape and positioning of gear (5) and wing (6), in chamber cluster (1), allow the definition of the orientation of axis (17) inside, or outside, the swept volume of the wing (6), and the part of the wing (1), that rotate about the axis (17). In this case, volume (19) is the sum of the constituent volumes of each chamber cluster (1), making up the assembly, but each chamber is separated by the other.
 3. The chamber cluster for a co-axial damper unit of a suspension module, according to claim 1, comprising the inner volume, and the flexible component, in which the wing is enclosed, which is in contact with the flexible part of the wing, allowing the partial sealing of the internal volume of the chamber cluster, (i.e. partial sealing of the variable volumes that are generated, on each side of the wing (6), during the rotary motion of the wing (6)), inside the chamber cluster (1), that is created, thus achieving the required damping characteristcs during the motion of the wings in the volume.
 4. The chamber cluster for a co-axial damper unit of a suspension module, according to claim 1, comprising an array of several chambers, about an axis, and around the torsion bar, resulting in an overall volume, in which a two-phase viscous fluid is affected by a device that alters the viscosity by electromagnetic means. The creation of an assembly of a co-axial damper unit, using several chamber clusters (1), allows the optimal damping of the primary suspension motion of the torsion bar (2), as well as the optimal cooling of the co-axial damper unit.
 5. The chamber cluster for a co-axial damper unit of a suspension module, according to claim 1, comprising a flexible component, that features a W-shape in section view, with a closed top section that is in contact with the inner surface of the chamber, and an open lower section with lips, that encloses the wing, follows the motion of the wing, maintaining partial sealing during the motion of the wing, thus achieving damping.
 6. The chamber cluster for a co-axial damper unit of a suspension module, according to claim 1, comprising a wing and a flexible part of the wing, which have slots and holes to induce optimal damping.
 7. The chamber cluster for a co-axial damper unit of a suspension module, according to claim 1, that is used in an assembly of a co-axial damper unit.
 8. The chamber cluster for a co-axial damper unit of a suspension module, according to claim 1, that is used in the construction of a suspension module.
 9. A vehicle comprising a suspension module, comprising a chamber cluster according to claim
 1. 10. The chamber cluster for a co-axial damper unit of a suspension module, according to claim 6, wherein the wing and flexible part of the wing comprise vortex inducing holes. 